Compacted olefin fibers

ABSTRACT

A polyolefin plaque is made by hot compaction of an assembly of fibres of the oriented polymer. It has been found to be beneficial to subject the fibres to a prior crosslinking process. Hot compaction is then less temperature-sensitive and produces plaques with excellent hot strength properties. Preferably the fibres have been subjected to prior stages of irradiation and annealing, both in a non-oxidising environment, for example acetylene.

This application is a continuation of application Ser. No. 10/717,553,filed Nov. 21, 2003, which is a continuation of application Ser. No.09/971,710, filed Oct. 9, 2001, which is a divisional of applicationSer. No. 09/285,256, filed Apr. 2, 1999, which is a continuation ofPCT/GB97/02675, filed Oct. 6, 1997, the entire content of which ishereby incorporated by reference in this application.

This invention relates to processes for the production of polymer sheetmaterials from oriented olefin polymer fibres and to the products ofsuch processes.

BACKGROUND OF THE INVENTION

GB 2253420B describes a process whereby an assembly of fibres of anoriented polymer may be hot compacted to form a sheet having goodmechanical properties. The process involves an initial processing stepin which the fibres are brought to and held at the compactiontemperature whilst subject to a pressure sufficient to maintain thefibres in contact, the contact pressure, and thereafter compacted at ahigher pressure for a few seconds, the compaction pressure. In theprocess a proportion of the fibre surfaces—most preferably from 5 to 10%by weight—melts and subsequently recrystallises on cooling. Thisrecrystallised phase binds the fibres together. Preferred materials foruse in this process are homo- and co-polymers of polyethylene.

The process of GB 2253420B can be used to produce complicated andprecisely shaped monolithic articles having high stiffness and strength,and good energy-absorbing properties. However, a drawback of thisprocess is the criticality of the compaction temperature, especially forpolyethylene. This is shown by Comparative Example A in GB 2253420B.

SUMMARY OF THE INVENTION

In accordance with the present invention there is provided a process forthe production of a monolithic article in which process an assembly offibres of an oriented polyolefin polymer is subjected to a compactionprocess wherein the assembly of fibres is maintained in intimate contactat an elevated temperature sufficient to melt a proportion of thepolymer, and is compressed, characterised in that prior to thecompaction process the fibres have been subjected to a crosslinkingprocess.

In some embodiments (referred to herein as “2-step compactions”) thecompaction process may comprise two distinct steps, namely a step ofmaintaining the assembly of fibres in intimate contact at an elevatedtemperature sufficient to melt a proportion of the fibre at a first,contact, pressure, and a subsequent compression step wherein theassembly is subjected to a second, compaction, pressure, higher than thecontact pressure—as in GB 2253420B.

In some embodiments (referred to herein as “1-step compactions”) thecompaction process may comprise a single step of maintaining theassembly of fibres in intimate contact at an elevated temperaturesufficient to melt a proportion of the fibre, and at a given pressure.In such embodiments there is no subsequent step of applying a higherpressure.

Preferably the monolithic article is an article which is shape stableunder its own weight, such as a plaque.

The crosslinking process may be a chemical crosslinking process,involving the use of a chemical reagent which forms reactive radicalsunder predetermined initiation conditions. Suitably the reagent may be acumene compound, or a peroxide, for example DMTBH or DCP, or a silane,for example a vinyl silane, preferably vinylmethoxy silane.

The crosslinking process may be an irradiation crosslinking processinvolving an ionising step comprising irradiating the fibres with anionising radiation, and then an annealing step comprising annealing theirradiated polymer at an elevated temperature.

For general information on known crosslinking processes, reference maybe made to Sultan & Palmlöf, “Advances in Crosslinking Technology”,Plast. Rubb. and Comp. Process and Appl., 21, 2, pp. 65-73 (1994), andto the references therein.

Irradiation crosslinking is believed to be particularly suitable, forthe process of the present application.

The pre-compaction process of crosslinking has been found to increasethe “temperature window” available for the subsequent compaction stage,and thus to make the compaction stage much easier to control. Further,compacted products produced by the process of the present invention haveexhibited superior hot strength properties, compared with compactedproducts made from fibres which have not been subject to priorcrosslinking.

The term “fibres” is used herein in a broad sense to denote strands ofpolyolefin polymer, however formed. The fibres subjected to priorcrosslinking may be non-woven fibres laid in a web, or may be comprisedwithin yarns, or constituted by bands or fibrillated tapes, for exampleformed by slitting films. If comprised within yarns or constituted bybands or fibrillated tapes, those yarns, bands or fibrillated tapes maybe laid together or they may be formed into a fabric, for example byweaving or knitting.

Suitably the fibres used in the process of the invention are formed frommolten polymer, for example as melt spun filaments.

Preferably the fibres used in the present invention have a weightaverage molecular weight in the range 10,000 to 400,000, preferably50,000 to 200,000.

The polyolefin polymer can be selected from polyethylene, polypropyleneor polybutylene, or copolymers comprising at least one of those olefinpolymers. The polyolefin polymer used in the process of the presentinvention may suitably be a polypropylene homopolymer or a copolymercontaining a major proportion of polypropylene. Advantageously it may bea polyethylene homopolymer or a copolymer containing a major proportionof polyethylene.

A polyethylene copolymer comprising a major proportion of polyethyleneas defined herein is one comprising more than 50% by weight ofpolyethylene. Preferably, it comprises more than 70% by weight ofpolyethylene, most preferably, more than 85% by weight of polyethylene.

A polyethylene polymer as defined herein may be unsubstituted, orsubstituted, for example by halogen atoms, preferably fluorine orchlorine atoms. Unsubstituted polyethylene polymers are howeverpreferred.

A polyethylene copolymer comprising a major proportion of polyethylenemay have one or more different copolymers, following copolymerisation ofethylene with, for example, one or more of propylene, butylene,butadiene, vinyl chloride, styrene or tetrafluoroethylene. Such apolyethylene copolymer may be a random copolymer, or a block or graftcopolymer. A preferred polyethylene copolymer is a ethylene-propylenecopolymer, having a major proportion of polyethylene and a minorproportion of polypropylene.

A polypropylene copolymer comprising a major proportion of polypropyleneas defined herein is one comprising more than 50% by weight ofpolypropylene. Preferably, it comprises more than 70% by weight ofpolypropylene, most preferably, more than 85% by weight ofpolypropylene.

A polypropylene polymer as defined herein may be unsubstituted, orsubstituted, for example by halogen atoms, preferably fluorine orchlorine atoms. Unsubstituted polypropylene polymers are howeverpreferred.

A polypropylene copolymer comprising a major proportion of polypropylenemay have one or more different copolymers, following copolymerisation ofpropylene with, for example, one or more of ethylene, butylene,butadiene, vinyl chloride, styrene or tetrafluoroethylene. Such apolypropylene copolymer may be a random copolymer, or a block or graftcopolymer. A preferred polypropylene copolymer is a propylene-ethylenecopolymer, having a major proportion of polypropylene and a minorproportion of polyethylene.

It is essential in the practice of the present invention that theprocess employs fibres which have been subjected to a crosslinkingprocess. However, the co-use of a polymer component (not necessarily apolyolefin) which has not been subjected to a crosslinking process,and/or of an inorganic filler material, is not excluded.

A polymer which has not been subjected to a crosslinking process may,when present, be present in an amount up to 50 vol % of the totalpolymer content of the article. Preferably, however, substantially theentire polymer content of the article derives from polyolefin polymerwhich has been subject to a crosslinking process.

An inorganic filler material may be present. An inorganic filler, whenpresent, may be present in an amount up to 60 vol % of the article,preferably 20 to 50 vol %. An inorganic filler material may, forexample, be selected from silica, talc, mica, graphite, metal oxides,carbonates and hydroxides and apatite, for example hydroxyapatite, abiocompatible calcium phosphate ceramic.

The preferred crosslinking process, involving irradiation crosslinking,will now be further defined.

Preferably, the environment for the annealing step which followsirradiation is a gaseous environment.

Preferably the irradiation step is effected in an environment which issubstantially free of oxygen gas. For example it could be performed invacuo or in the presence of an inert liquid or gas. Preferably howeverthe environment for the irradiation step comprises a monomeric compoundselected from alkynes, and from alkenes having at least two doublebonds.

Preferably, the annealing step which follows irradiation is carried outin an environment which is substantially free of oxygen gas but whichcomprises a monomeric compound selected from alkynes, and from alkeneshaving at least two double bonds.

There is no necessity for the environments to be the same, in theirradiation and annealing steps. Indeed there is no necessity for saidmonomeric compound used during the irradiation step to be the same assaid monomeric compound used in the annealing step; the monomericcompound used in the irradiation step could be replaced in whole or inpart by a different monomeric compound for the annealing step. Howeverit is believed that the properties desired of said monomeric compound inthe irradiation step will generally be the same as those required in theannealing step, so there will generally be no necessity to effect awhole or partial replacement. Most conveniently, therefore, themonomeric compound is the same throughout. In some cases however it maybe advantageous to supply a further charge of said monomeric compound,as the process proceeds.

For either or both steps, a mixture of monomeric compounds could beemployed.

The environment employed for the irradiation and/or the annealing stepsis preferably constituted entirely by said monomeric compound, but mayalso comprise a mixture being said monomeric compound together with oneor more other components, for example an inert gas or liquid. Suitablythe said monomeric compound is gaseous at least under the treatmentconditions employed and is employed in the irradiation and/or annealingsteps at a pressure, or partial pressure in the case of a mixture, inthe range of 0.2-4 atmospheres (2×10⁴ Pa-4×10⁵ Pa), preferably 0.5-2atmospheres (5×10⁴ Pa-2×10⁵ Pa), most preferably 0.3-1 atmospheres(3×10⁴ Pa-1×10⁵ Pa).

Preferred monomeric compounds for use in the present invention, ineither or both of the irradiation and annealing steps, are alkynes, andalkenes having at least two double bonds, which alkenes are notsubstituted by halogen atoms. They are desirably gaseous under thetreatment conditions employed and should be able to diffuse into thepolyolefin polymer under the treatment conditions employed. Preferredare unsubstituted alkynes or alkenes i.e. alkynes or alkenes made upsubstantially entirely by hydrogen and carbon atoms. Examples areunsubstituted C₂₋₆ alkynes, preferably having only one triple bond, forexample acetylene, methyl acetylene, dimethyl acetylene an dethylacetylene (of which species acetylene is preferred) and unsubstitutedC₄₋₈ alkenes having at least two double bonds, preferably only twodouble bonds, for example 1,3-butadiene, 1,3-pentadiene, 1-3-hexadiene,1,4-hexadiene and 1,3,5-hexatriene (of which species 1,3-butadiene ispreferred).

One preferred class of alkenes for use in the present invention has atleast two conjugated double bonds, thus including 1,3-butadiene,1,3-petadiene, 1,3-hexadiene and 1,3,5-hexatriene. Preferably theconjugation extends throughout the length of the compound, as is thecase with 1,3-butadiene and 1,3,5-hexatriene.

Another preferred class of alkenes for use with the present inventionhas double bonds at least as the terminal bonds in the compounds, thusincluding 1,3-butadiene and 1,3,5-hexatriene.

A particularly preferred class of alkenes has at least two conjugateddouble bonds, preferably with one conjugation extending throughout thelength of the compounds, and double bonds at least as the terminal bondsof the compounds. Compounds of this type thus include 1,3-butadiene and1,3,5-hexatriene.

Preferably said alkyne or alkene having at least two double bonds is thesole crosslinking agent employed in the irradiation step and/or theannealing step.

Acetylene is an especially preferred monomeric compound for use in thepresent invention. Preferably acetylene is used as substantially thesole said monomeric compound both in the irradiation step and in theannealing step.

Suitably the irradiation step is affected at a temperature not exceeding100° C., preferably not exceeding 80° C. A preferred range is 0-50° C.,most preferably 15-30° C. Conveniently the step is effected at ambienttemperature.

In carrying out the process of this invention, any ionizing radiationcan be employed. In practice, however, the types of ionizing radiatonwhich can be used with greatest practicality are electron beams,ultra-violet radiation and, especially, γ-rays.

The radiation dose is suitably in the range 0.5 to 100 MRads inclusive,preferably 1 to 50 MRads inclusive, most preferably 2 to 20 MRadsinclusive. For many applications a radiation dose of 3 to 10 MRadsinclusive appears very favourable.

Preferably the polyolefin polymer is annealed at a temperature of atleast 60° C., preferably at a temperature in the range 80 to 120° C.inclusive.

Preferably the polyolefin polymer is annealed at an annealingtemperature at least 20° C. below its melting point, most preferably atan annealing temperature which is below its melting point by atemperature differential in the range 20 to 50° C., inclusive, mostpreferably, 30 to 40° C. inclusive.

The period for which annealing is carried out is not thought to becritical, provided that the time is sufficient for substantially all ofthe polymer which has been irradiated to reach the said annealingtemperature and for substantially all of the radicals formed to havereacted. This can be assessed by trial and error following ESR ormechanical testing of irradiated and annealed samples; the presence ofunreacted radicals is believed to lead to chain scission and diminutionin mechanical properties.

Suitably the polyolefin polymer after the irradiation and annealingsteps has a gel fraction at least 0.4, preferably at least 0.5.Preferably the polyolefin polymer after the irradiation and annealingsteps has a gel fraction no greater than 0.85, preferably no greaterthan 0.75. A particularly preferred gel fraction is in the range 0.55 to0.7, most preferably 0.6 to 0.65.

In accordance with the present invention there is provided a polyolefinpolymer monolith prepared in accordance with the process of theinvention, as defined above.

In relation to the compaction stage which follows the steps ofirradiation and annealing, the description in GB 2253420B is in generalapplicable to the modified process of the present invention, for examplein relation to treatment times, temperature, proportion of materialwhich is to melt, the assembly of the fibres and molecular weights, andthe description of GB 2253420B may be regarded as incorporated into thepresent specification by reference, insofar as it applies to theproduction of polyolefin articles. However, the preferred pressureconditions are different, and are set out below.

In 2-step compactions in accordance with the present invention thecontact pressure is suitably in the range 0.01 to 2 MPa, preferably 0.1to 1 MPa, most preferably 0.3 to 0.7 MPa; and the compaction pressure issuitably in the range 0.1 to 50 MPa, preferably 0.2 to 10 MPa, mostpreferably 0.3 to 7 MPa. In such 2-stage processes the compactionpressure should be higher than the contact pressure, suitably by afactor of at least 2, and preferably by a factor of at least 4.

In 1-step compactions in accordance with the present invention the(single) pressure applied is suitably in the range 0.1 to 10 MPa,preferably 0.2 to 5 MPa, most preferably 0.3 to 4 MPa.

It is especially preferred that the pressure, or maximum pressure, issuch that the process may be carried out in an autoclave, or in a beltpress or other apparatus in which the assembly is fed through acompaction zone in which it is subjected to said elevated temperatureand said pressure.

A further difference between the present invention and that of GB2253420B is that in the process of the invention the proportion of thepolymer which melts is suitably at least 10% by weight, preferably 10 to50% by weight.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be further described with reference to theaccompanying drawings, in which:

FIG. 1 is a graph of percentage of melting peak remaining againsttemperature for TENFOR;

FIG. 2 is a graph of percentage of melting peak remaining againsttemperature for CERTRAN;

FIG. 3 is a schematic showing a U-shaped former around which fiber iswound;

FIG. 4 is a schematic of a yarn translation mechanism;

FIGS. 5-7 illustrate wound yarn laid over a mold;

FIG. 8 is a graph of modulus of irradiated TENFOR plaques againsttemperature;

FIG. 9 is a graph of longitudinal strength for irradiated TENFOR plaquesagainst temperature;

FIG. 10 is a graph of transverse strength for irradiated TENFOR plaquesagainst temperature;

FIG. 11 is a graph of tensile modulus for hot compacted CERTRAN againsttemperature;

FIG. 12, is a graph of strength for normal and cross-linked CERTRANagainst temperature;

FIG. 13 is a graph of stress strain plots for E-beam irradiated CERTRANagainst strain;

FIG. 14 is a graph of strain curves for hot compacted CERTRAN againststrain;

FIG. 15 is a graph of failure strength of CERTRAN against temperature.

EXAMPLES

The invention will now be further described, by way of example, withreference to the examples which follow.

Samples

In the first examples, the materials used were commercially availableoriented melt spun homopolymeric polyethylene, sold as a 1800 deniermultifilament yarn under the Trade Mark TENFOR, and as a 250 deniermultifilament yarn, under the Trade Mark CERTRAN. The plolyethylene ofTENFOR and CERTRAN is of the same grade, and is characterised asfollows: Tensile Modulus Breaking Initial Molecular Weight StrengthSecant 2% Mw Mn Process GPa GPa GPa 130,000 12,000 melt spun 1.3 58 43

Pre-Treatment and Annealing

A bobbin of the TENFOR polyethylene was subjected to γ-radiation at alow dose rate (less than 0.1 MRad/hour) at ambient temperature under anatmosphere of acetylene at a pressure of about 5×10⁴ Pa aboveatmospheric. The total dose was 7.39 MRad. After irradiation the samplewas annealed for 2 hours at 110° C. under an atmosphere of acetylene ata pressure of 5×10⁴ Pa above atmospheric. The resultant gel content was80.9%. Physical properties of the resultant irradiated and annealedfibre were as follows:

Density: 979.3±0.1 kg/m³

Tensile modulus: 30±1 GPa (fibre straight off the bobbin; 1%/min)

Tensile strength: 0.82 GPa±0.01 GPa (fibre straight off the bobbin;1%/min)

The CERTRAN polyethylene yarns, ten 3 g hanks, were wound onto glasstubes and were subjected to electron beam irradiation at a fast doserate (0.655 MRad/min) for 7 minutes at ambient temperature under anatmosphere of acetylene at 3×10⁴ Pa above atmospheric pressure. Becauseof the high dose rate the temperature of the sample increased duringirradiation. No external temperature control was used. The total dosewas about 4.6 MRad. After irradiation the sample was annealed for 2hours at 90° C. under an atmosphere of acetylene at 3×10⁴ Pa aboveatmospheric pressure. Consequently eight samples with gel contentsbetween 69.4% and 71.8% were produced with the remaining two sampleshaving gel contents of 77% and 84%.

Preliminary DSC experiments were performed on the irradiated andannealed TENFOR and CERTRAN yarns, in comparison to untreated fibres, toassess melting thereof. Partial melting experiments were carried out, inwhich the yarns were held for ten minutes at a given SOAK temperaturebefore being cooled and scanned. This allowed a comparison of thenormalised area of the DSC melting peak for different amounts of partialmelting, and hence gave an indication of the amount of fibre which wasdestroyed by melting, at that temperature. FIG. 1 is a graph in whichthe results for TENFOR are plotted, and it will be seen that theunirradiated yarn shows a rapid fall off in fibre content between 136°C. and 138° C. In contrast, the fall off in fibre content of theirradiated and annealed fibre was gradual, with some material beingretained unmelted up to 144° C. Corresponding testing was carried out onCERTRAN polyethylene having the 77% gel content, and this yielded asimilar result, as shown in FIG. 2. The results from these preliminarytests indicated that the irradiated and annealed yarns should have awider range of temperatures over which they could be compacted, than thecorresponding untreated yarns. In particular, the lack of a sudden dropin fibre content indicated that the compaction process should be muchmore controllable, with the yarns crosslinked by irradiation andannealing.

Gel contents were measured by the method as described in the Journal ofPolymer Science: Part B: Polymer Physics, 1993, Vol. 31, p. 809 (R. A.Jones, G. A. Salmon and I. M. ward).

Compaction

Hot compacted samples were prepared from the TENFOR irradiated andannealed yarns in the following way. The TENFOR was would around aU-shaped former 80 mm wide and with a traverse of 55 mm, as shown inFIG. 3. The winding of the yarn onto the former was carefully controlledso that there were 100 windings of the yarn over the 55 mm traverse,this being achieved by revolving the former, and by a yarn translationmechanism, as shown schematically in FIG. 4. The yarn was thereby woundneatly, uniformly and unidirectionally. Several traverses were carriedout so that there were several layers of yarn, generally 6, about theformer, this number leading to compacted plaques approximately 2.25 mmthick. The wound yarn was then laid over a mould 55 mm square, andhaving two side walls and two open ends, as shown in FIGS. 5-7. A lid 55mm square was then fitted over the mould, against the wound yarn, andthe former was then removed. The mould assembly was then subjected to anelevated temperature at a first pressure, the contact pressure, for aset period of time, the contact time, and then subjected to a second,higher, pressure, the compaction pressure, for a shorter period of time,at the same temperature. For all samples cooling was initiated as soonas the compaction pressure was applied, thus controlling a temperaturerise of up to 2° C. upon compaction. At 144° C. and above the saidpressure increased naturally the contact time, and no attempt was madeto prevent this.

In interpreting the results of the later compaction tests it should benoted that superheating effects due to constraint raise the optimumtemperature by about 4° C., compared with the DSC experiments describedearlier.

Table 1 below sets out the processing regimes for the TENFOR samples.TABLE 1 Compaction Methods for Crosslinked Tenfor Plaques Contact N^(o)Contact Compaction Temp Time of Layers Pressure Pressure Pressure (° C.)(mins) Of Fibre (MPa) (MPa) Build 140 15, 10, 5, 2 6 0.35 34 No 141 15,5 6 0.35 34 No 143 15 6 0.35 34 No 145 15 6 0.35 17 Yes 148 15 6 0.35 17Yes 150 15 4 0.35 8.4 Yes 152 15 6 0.35 3.5 Yes

In subsequent experiments it did not prove possible to achievecompaction in tests performed with contact pressures significantly above0.35 MPa at a temperature of 140° C. In experiments performed at contactpressures of 0.52 and 0.7 MPa and a temperature of 140° C. the fibre inthe plaques did not appear to have to undergone any melting, the plaquescould be broken quite easily by hand along the yarn axis, and the yarnwas still clearly visible.

Samples were prepared in a similar manner with irradiated and annealedCERTRAN yarn, but using 32 layers of windings, because of the lowerdenier of CERTRAN.

Table 2 below sets out the compaction regimes for the CERTRAN fibres.TABLE 2 Methods Used To Produce Compacted Plaques of Crosslinked CertranTemp Contact Contact Compaction Time Number Pressure Pressure (° C.)(mins) Of Layers (MPa) (MPa) 141 10 32 0.35 37 145 10 32 0.35 17 150 1032 0.35 10

Testing

The flexural modulus and flexural strength of the samples in the yarndirection or perpendicular to the yarn direction, as appropriate, weremeasured.

Due to the size limitation of the plaques the tests could not be carriedout exactly to ASTM standards. The equipment used was compliant withASTM D790, and three point bending was used as described in method 1 ofthis standard. The dimensions of the specimens tested were: LongitudinalSpan 40 mm Width  5 mm Thickness governed by plaque Transverse Span 30mm Width 10 mm Thickness governed by plaque

In general this means that the ratio of thickness to span was around 16to 1. In all cases the rate of crosshead motion was 1 mm per minute.

Initial longitudinal flexural modulus was determined by taking the slopeof the initial part of the output curve and using the following formula.${Modulus} = {\left( \frac{Load}{Deflection} \right) \times \frac{{span}^{3}}{4 \times {thickness}^{3} \times {width}}}$

Flexural strength was determined by taking the peak load before breakingand using the following formula.${Strength} = \frac{6 \times {load} \times {span}}{4 \times {width} \times {thickness}^{2}}$

Properties of Compacted TENFOR

All of the measured mechanical properties are shown in Table 3 below andFIG. 8, 9 or 10 set out the longitudinal flexural modulus, longitudinalflexural strength and transverse flexural strength of samples given a 15period at the contact pressure at the stated temperatures. TABLE 3Mechanical Properties of Crosslinked Tenfor Plaques CompactionLongitudinal Longitudinal Transverse Method Flexural Flexural Flexural(Contact Modulus Strength Strength Density time; ° C.) (GPa) (MPa) (MPa)(Kg/m³)  2 min 140 12.9 152 19 —  5 min 140 19.7 139 20 — 10 min 14019.5 158 27 — 15 min 140 19.5 146 11 973.3 15 min 141 17.0 124 18 973.115 min 143 13.1 151 12 972.4 15 min 145 11.8 141 18 965.9 15 min 148 7.0— — 964.7 15 min 150 2.1 125 31.2 963.1 15 min 152 2.25 132 32.6 962.4

For a fixed contact time of 15 minutes the longitudinal flexural modulusdecreases steadily from 19.5 GPa at 140° C. to 2.5 GPa at 152° C., FIG.8. The longitudinal flexural strengths remain relatively constant from140° C. to 152° C., at around 140 MPa, FIG. 9. The transverse flexuralstrengths are constant around 15 MPa from 140° C. to 145° C., and thenincrease with increasing temperature, FIG. 10.

Clearly, the properties of the plaques vary with temperature and, basedon the compactions at 140° C., contact time. The optimum contact timecan be determined by trial and error. The optimum temperature willdepend on the properties required. However, the results make it clearthat, as anticipated by the DSC work described earlier, there is areasonable degree of latitude, in terms of the temperature, in carryingout compaction. Within the 12° C. range in the tests, there were noabrupt fall-offs in properties of the plaques, as would be expected withcorresponding compaction of unirradiated yarns, using the method asdescribed in GG 2253420B.

Comparative Tests on TENFOR

Further experiments were carried out to compare the properties ofplaques moulded from crosslinked and normal (non-crosslinked) TENFORpolyethylene.

The data for normal TENFOR was gathered using the same method as for thecrosslinked TENFOR. The only differences were that the contact pressurewas 0.7 MPa as compared to 0.35 MPa for the crosslinked material, andthe contact time was 10 minutes instead of 15 minutes.

The results are set out in Table 4 below. This mentions degrees Celsiusabove the onset of compaction, instead of giving absolute temperaturevalues. Temperature is indicated in this way because the crosslinked andnon-crosslinked materials started to compact at different temperatures.We believe this is due to crosslinking delaying the onset of melting.TABLE 4 Comparison of Mechanical Properties of Crosslinked andNon-crosslinked TENFOR a) Longitudinal Flexural Modulus Degrees CelsiusAbove onset of Non-crosslinked Crosslinked Compaction (GPa) (GPa) Onset17.5 19.5 1 15.5 17.0 2 16.7 3 completely melted 13.1 5 11.8 8 7.0 10 2.1 b) Longitudinal Flexural Strength Degrees Celsisus above onset ofNon-crosslinked Crosslinked Compaction (MPa) (MPa) Onset 139.5 146 1108.6 124 2 117.8 3 completely melted 151 5 141 8 10  125 c) TransverseFlexural Strength Degrees Celsius above onset of Non-crosslinkedCrosslinked compaction (MPa) (MPa) Onset 23.5 11.0 1 38.5 18.0 2 38.5 3completely melted 12.0 5 18.0 8 10  31.2

Properties of Compacted CERTRAN

The mechanical properties of the plaques compacted from the irradiatedand annealed CERTRAN fibres were tested in the same way as describedabove for plaques of TENFOR fibres. The results are shown in Table 5below. TABLE 5 Mechanical Properties of Irradiated CRETRAN PlaquesLongitudinal Longitudinal Transverse Compaction Flexural FlexuralFlexural Temperature Modulus Strength Strength (° C.) (GPa) (MPa) (MPa)141 11.3 20.8 145 5.7 127 25.5 150 4.9 111 30.2

The lower than expected modulus results, when combined with therelatively high transverse strengths and the observation that morematerial extruded from the mould than in the case of the TENFOR suggeststhat more fibre was destroyed by melting, than with the TENFOR. Thus itwas concluded that compaction conditions are slightly different than forTENFOR, and a higher contact pressure must be used.

Regrettably all the irradiated and annealed CERTRAN had been used and nofurther compaction could be attempted. However, even these preliminaryresults indicate that a wide “temperature window” should be availablefor compaction.

Elevated Temperature Properties—CERTRAN

Plaques made from crosslinked and non-crosslinked CERTRAN were testedfor their mechanical properties at elevated temperature.

A. Properties of 63% Gel Fraction Materials.

A piece of woven CERTRAN cloth 51 cm long by 13 cm wide was wound arounda former. For irradiation it was placed in a glass tube and irradiationwas carried out by electron beam. The electron beam irradiation was to atotal dose of 4.5 MRad, in an acetylene environment at a pressure of3×10⁴ Pa above atmospheric, at ambient temperature. The polymer was thenannealed for 2 hours at 90° C. in acetylene, at a pressure of 3×10⁴ Paabove atmospheric. The resultant gel fraction was 63%. The treated clothwas then compacted using a two-stage process as described above, at atemperature of 144° C., with a contact time/pressure of 10 minutes/0.35MPa, followed by compaction at 7 MPa. Dumbbell-shaped samples of 26 mmgauge length were cut from it for tensile testing. The results of thesetensile tests, carried out over a range of temperatures, and performedat a nominal strain rate of 20% per minute, are shown in FIGS. 11 and12. It will be seen that the crosslinked CERTRAN plaques have better hottemperature failure strength, than the non-crosslinked plaques. FIGS. 13and 14 show stress-strain curves of the 63% gel fraction crosslinkedmaterial and the untreated fibre respectively over a range oftemperatures. It is seen that the cross linking substantially changesthe stress-strain behaviour.

B. Properties of 85% Gel Fraction Materials.

FIG. 15 shows the tensile failure strengths of samples prepared from 85%gel fraction CERTRAN yarn. The yarn had been irradiated by γ radiationto a total dose of 5 MRad, in acetylene at a pressure of 5×10⁴ Paatmospheric, at ambient temperature; then annealed for 2 hours at 90° inacetylene, at the same pressure. The treated polymer was then compactedusing a two-stage process as described above, at a temperature of 144°C. with a contact time/pressure of 10 minutes/0.35 MPa, and a compactionpressure of 7 MPa. The plaques thus formed were tested at differenttemperatures, and compared to untreated samples. It will be seen thatthe pre-irradiated plaques have substantially better failure strengthsat elevated temperatures. In this case those plaques had lower failurestrength at 20° C. This is thought to be due to the fact that the gelfraction, at 85%, is higher than is optimal.

Single Stage Compaction—CERTRAN

10 kg of woven CERTRAN cloth, 107 cm wide, was placed in a purpose buildcylinder, which was first evacuated and then pressurised to 6×10⁴ Pawith acetylene. Irradiation was carried out using γ radiation to a doseof 1.8 MRad at ambient temperature. After irradiation the cylinder andcloth were repressurised to 6×10⁴ Pa with acetylene and annealed at 90°C. for 8 hours. After annealing the cloth was removed from the cylinderand scoured to remove any by-products of the crosslinking process. Inaddition it was found that optimum compaction was achieved if thesurface of the cloth was lightly abraded over a sandpaper covered rollerto further remove any crosslinking by-products. The gel content of thecrosslinked cloth was measured as 62%.

Compaction experiments were carried out at 144° C. using a single stageprocess with a pressure of 0.7 MPa used throughout. Dumbbell sampleswere cut from the compacted sheets and tensile modulus and strength weredetermined at 20° C. and 80° C. Table 6 below shows a comparison ofthese results with results for compacted crosslinked CERTRAN cloth usinga two stage process (compaction temperature 144° C., contact pressure0.35 MPa and compaction pressure 7 MPa, also lightly abraded beforecompaction) and results for compacted non-crosslinked CERTRAN cloth(compaction temperature 139° C., contact pressure 0.7 MPa and compactionpressure 7 MPa, non-abraded). TABLE 6 Non-crosslinked CrosslinkedCrosslinked Compaction Temperature 139° C. 144° C. 144° C. Contactpressure 0.7 MPa 0.35 MPa 0.7 MPa Compaction pressure 7 MPa 7 MPa 0.7MPa Tensile Modulus (20° C.) 10.0 GPa 9.8 GPa 10.1 GPa Tensile Strength(20° C.) 200 MPa 200 MPa 220 MPa Tensile Modulus (80° C.) 2.7 GPa 5.3GPa Not measured Tensile Strength (80° C.) 20 MPa 100 MPa 107 MPa

In general it may reasonably be concluded from the totality of theexperiments carried out, that the properties of compacted plaquesprepared from polyolefin given a pre-treatment of irradiation anannealing in order to achieve crosslinking are more controllable due tothe wider melting range, and exhibit certain improvements in mechanicalproperties, particularly failure strength at elevated temperatures.

1. A process for the production of a monolithic article in which processan assembly of fibres of an polyolefin oriented polymer is subjected toa compaction stage wherein the assembly of fibres is maintained inintimate contact at an elevated temperature sufficient to melt aproportion of the polymer, and is compressed, characterised in thatprior to the compaction stage the fibres have been subjected to acrosslinking process.
 2. A process as claimed in claim 1, wherein thecompaction stage comprises two distinct steps, namely a step ofmaintaining the assembly of fibres in intimate contact at an elevatedtemperature sufficient to melt a proportion of the fibre at a first,contact, pressure, and a subsequent compression step wherein theassembly is subjected to a second, compaction, pressure, higher than thecontact pressure.
 3. A process as claimed in claim 1, wherein thecompaction stage comprises a single step of maintaining the assembly offibres in intimate contact at a given pressure and at an elevatedtemperature sufficient to melt a proportion of the fibres.
 4. A processas claimed in claim 1, wherein the crosslinking process is anirradiation crosslinking process involving an ionising step whichcomprises irradiating the fibres with an ionising radiation, and then anannealing step comprising annealing the irradiated polymer at anelevated temperature.
 5. A process as claimed in claim 4, wherein theirradiation step is carried out in an environment which is substantiallyfree of oxygen gas and which comprises a monomeric compound selectedfrom alkynes, and from alkenes having at least two double bonds.
 6. Aprocess as claimed in claim 5, wherein said environment comprisesacetylene.
 7. A process as claimed in claim 4, wherein the annealingstep which follows irradiation is carried out in an environment which issubstantially free of oxygen gas and which comprises a monomericcompound selected from alkynes, and from alkenes having at least twodouble bonds.
 8. A process as claimed in claim 7, wherein saidenvironment comprises acetylene.
 9. A process as claimed in claim 1,wherein the fibres used in the process as formed from molten polymer.10. A process as claimed in claim 1, wherein the fibres have a weightaverage molecular weight in the range 10,000 to 400,000.
 11. A processas claimed in claim 10, wherein the fibres have a weight averagemolecular weight in the range 50,000 to 200,000.
 12. A process asclaimed in claim 1, wherein the polyolefin polymer is selected from thegroup comprising polypropylene homopolymer, a copolymer containing amajor proportion of polypropylene, polyethylene homopolymer and acopolymer containing a major proportion of polyethylene.
 13. A processas claimed in claim 4, wherein the irradiation step is effected at atemperature not exceeding 100° C.
 14. A process as claimed in claim 13,wherein the irradiation step is effected at a temperature in the range0-50° C.
 15. A process as claimed in claim 4, wherein the ionizingradiation is selected from electron beam, ultraviolet and γ-radiation.16. A process as claimed in claim 4, wherein the radiation dose is inthe range 0.5 to 100 MRads.
 17. A process as claimed in claim 16,wherein the radiation dose is in the range 2 to 20 MRads.
 18. A processas claimed in claim 4, wherein the polyolefin polymer is annealed at atemperature of at least 60° C.
 19. A process as claimed in claim 4,wherein the polyolefin polymer after the irradiation and annealing stepshas a gel fraction of at least 0.4.
 20. A process as claimed in claim19, wherein the polyolefin polymer after the irradiation and annealingsteps has a gel fraction in the range 0.55 to 0.7.
 21. A process asclaimed in claim 2, wherein the contact pressure is in the range 0.01 to2 MPa, and the compaction pressure is in the range 0.1 to 50 MPa, but ishigher than the contact pressure.
 22. A process as claimed in claim 21,wherein the contact pressure is in the range 0.3 to 0.7 MPa and thecompaction pressure is in the range 0.6 to 7 Mpa, but is at least doublethe contact pressure.
 23. A process as claimed in claim 3, wherein thesingle pressure applied is in the range 0.1 to 10 MPa.
 24. A process asclaimed in claim 1, wherein the proportion of the polymer which meltsduring the compaction stage is 10 to 50% by weight.
 25. A process asclaimed in claim 1, which process employs an inorganic filler material,such that the filler is present in the compacted monolithic article inan amount up to 60 vol % of the article.
 26. A polyolefin polymermonolith prepared in accordance with the process of the invention, asclaimed in claim 1.